U.S. patent application number 12/742603 was filed with the patent office on 2010-09-30 for multi-stage debulk and compaction of thick composite repair laminates.
Invention is credited to Vance N. Cribb, Dumitru R. Jitariu, Denver R. Whitworth.
Application Number | 20100243146 12/742603 |
Document ID | / |
Family ID | 40678999 |
Filed Date | 2010-09-30 |
United States Patent
Application |
20100243146 |
Kind Code |
A1 |
Whitworth; Denver R. ; et
al. |
September 30, 2010 |
Multi-Stage Debulk and Compaction of Thick Composite Repair
Laminates
Abstract
A method for fabricating a repair laminate for a composite part
having an exposed surface includes applying a release film to the
exposed surface and forming an uncured ply stack assembly on the
release film. The uncured ply stack assembly is formed by forming
and compacting a series of uncured ply stacks. The release film and
ply stack assembly is then removed from the exposed surface. A
bonding material is then applied to the exposed surface, and the
uncured ply stack assembly is applied to the bonding material. The
ply stack assembly and bonding material are then cured.
Inventors: |
Whitworth; Denver R.; (North
Richland Hills, TX) ; Cribb; Vance N.; (Grapevine,
TX) ; Jitariu; Dumitru R.; (Flower Mound,
TX) |
Correspondence
Address: |
LAW OFFICES OF JAMES E. WALTON, PLLC
1169 N. BURLESON BLVD., SUITE 107-328
BURLESON
TX
76028
US
|
Family ID: |
40678999 |
Appl. No.: |
12/742603 |
Filed: |
November 26, 2008 |
PCT Filed: |
November 26, 2008 |
PCT NO: |
PCT/US08/84969 |
371 Date: |
May 12, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60990017 |
Nov 26, 2007 |
|
|
|
Current U.S.
Class: |
156/249 |
Current CPC
Class: |
B32B 38/10 20130101;
B32B 37/1018 20130101; B32B 43/00 20130101; B32B 2305/72 20130101;
B29C 73/10 20130101; B32B 2605/18 20130101; Y10T 428/20 20150115;
B29C 37/0075 20130101; B32B 37/06 20130101 |
Class at
Publication: |
156/249 |
International
Class: |
B32B 38/10 20060101
B32B038/10 |
Claims
1. A method for fabricating a repair laminate for a composite part
having an exposed surface, comprising: applying a release film to
the exposed surface; applying a first ply stack to the release
film, the first ply stack having a first plurality of uncured
plies; compacting the first plurality of uncured plies; applying a
second ply stack to the first ply stack, the second ply stack
having a second plurality of uncured plies; compacting the second
plurality of uncured plies; removing the release film and the first
and second ply stacks from the composite part; applying bonding
material to the exposed surface; applying a ply stack assembly
comprising the first and second ply stacks to the bonding material
on the exposed surface; and curing the ply stack assembly and
bonding material.
2. The method according to claim 1, wherein at least one of the
first and second pluralities of uncured plies includes
polymeric-matrix composite materials.
3. The method according to claim 1, wherein at least one of the
first and second ply stacks comprises fewer than ten uncured
plies.
4. The method according to claim 1, wherein the compacting of the
first ply stack includes at least partially enclosing the first ply
stack within a sealing bag and attaching the sealing bag to the
exposed surface to create an air tight seal around the first ply
stack.
5. The method according to claim 4, wherein the compacting of the
first ply stack includes evacuating gases from within the sealing
bag.
6. The method according to claim 5, wherein the compacting of the
first ply stack includes increasing vacuum pressure within the
sealing bag to a first pressure level for a first predetermined
amount of time.
7. The method according to claim 6, wherein the compacting of the
first ply stack includes increasing vacuum pressure within the
sealing bag to a second pressure level for a second predetermined
amount of time.
8. The method according to claim 4, wherein the compacting of the
first ply stack includes increasing the temperature within the
sealing bag to a first temperature for a first predetermined amount
of time.
9. The method according to claim 1, wherein the compacting of the
first ply stack includes increasing the temperature of the first
ply stack to a first temperature for a first predetermined amount
of time.
10. The method according to claim 1, wherein the curing of the ply
stack assembly includes: at least partially enclosing the ply stack
assembly within a sealing bag and attaching the sealing bag to the
exposed surface to create an air tight seal around the ply stack
assembly; increasing vacuum pressure within the sealing bag; and
increasing the temperature within the sealing bag to a curing
temperature.
11. A method for fabricating a repair laminate for a composite part
having an exposed surface, comprising: applying a release film to
the exposed surface; forming an uncured ply stack assembly that
comprises a plurality of uncured ply stacks, the forming of the
uncured ply stack assembly including, for each uncured ply stack:
forming the uncured ply stack over the exposed surface, the uncured
ply stack including a plurality of uncured plies; and applying a
vacuum and heat to the thus formed uncured ply stack prior to
forming another uncured ply stack over the exposed surface, wherein
a first-formed ply stack is applied to the release film, and
wherein each subsequently-formed ply stack is applied to a
previously-formed ply stack; removing the release film and the
uncured ply stack assembly from the composite part; applying
bonding material to the exposed surface; applying the uncured ply
stack assembly to the bonding material on the exposed surface; and
curing the uncured ply stack assembly and bonding material.
12. The method according to claim 11, wherein at least one of the
plurality of uncured ply stacks includes one or more uncured plies
comprising polymeric-matrix composite materials.
13. The method according to claim 11, wherein at least one of the
uncured ply stacks comprises fewer than ten uncured plies.
14. The method according to claim 11, wherein the forming of the
uncured ply stack assembly further includes, for each uncured ply
stack, at least partially enclosing the uncured ply stack within a
sealing bag and attaching the sealing bag to the exposed surface to
create an air tight seal around the uncured ply stack.
15. The method according to claim 14, wherein the applying of the
vacuum includes evacuating gases from within the sealing bag.
16. The method according to claim 15, wherein the applying of the
vacuum includes increasing vacuum pressure within the sealing bag
to a first pressure level for a first predetermined amount of
time.
17. The method according to claim 16, wherein the applying of the
vacuum includes increasing vacuum pressure within the sealing bag
to a second pressure level for a second predetermined amount of
time.
18. The method according to claim 14, wherein the applying of the
heat includes increasing the temperature within the sealing bag to
a first temperature for a first predetermined amount of time.
19. The method according to claim 11, wherein the applying of the
heat includes increasing the temperature of the ply stack to a
first temperature for a first predetermined amount of time.
20. The method according to claim 11, wherein the curing of the
uncured ply stack assembly includes: at least partially enclosing
the uncured ply stack assembly within a sealing bag and attaching
the sealing bag to the exposed surface to create an air tight seal
around the uncured ply stack assembly; increasing vacuum pressure
within the sealing bag; and increasing the temperature within the
sealing bag to a curing temperature.
Description
TECHNICAL FIELD
[0001] The present invention relates to methods of fabricating
laminates made from polymeric-matrix composite materials.
DESCRIPTION OF THE PRIOR ART
[0002] Parts made from polymeric-matrix composite materials form
many components in modern automotive, aeronautical, and marine
vehicles, as well as components in many other types of equipment
and structures. Such parts may, from time to time, become damaged,
thus requiring repair or replacement. It is often required or at
least more cost effective to repair a damaged part than to replace
the part. Conventional methods of repairing polymeric-matrix
composite parts require the use of specialized tooling and double
vacuum tool/processes, which require multiple staging operations
and cure cycles, or specialized lay-up tools and autoclave
processing, which is expensive and often impractical when used to
facilitate a repair.
[0003] There are many ways to repair damaged polymeric-matrix
composite parts that are well known in the art; however,
considerable shortcomings remain.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The novel features believed characteristic of the invention
are set forth in the description. However, the invention itself, as
well as, a preferred mode of use, and further objectives and
advantages thereof, will best be understood by reference to the
following detailed description when read in conjunction with the
accompanying drawings, in which the leftmost significant digit(s)
in the reference numerals denote(s) the first figure in which the
respective reference numerals appear, wherein:
[0005] FIG. 1 is an elevated side view of uncured plies applied to
a composite part according to the method of the present
application.
[0006] FIG. 2 is an elevated side view of a sealing bag enclosing a
ply stack on the composite part according to the method of the
present application.
[0007] FIG. 3 is an elevated side view of multiple ply stacks on
the composite part according to the method of the present
application.
[0008] FIG. 4 is an elevated side view of a bonding layer disposed
between ply stacks and the composite part according to the method
of the present application.
[0009] FIG. 5 is an elevated side view of a sealing bag enclosing
multiple ply stacks on the composite part according to the method
of the present application.
[0010] FIG. 6 is an elevated side view of a cured composite layer
on the composite part according to the method of the present
application.
[0011] FIG. 7 is an elevated side view of an alternative embodiment
of the composite part according to the method of the present
application.
[0012] While the invention is susceptible to various modifications
and alternative forms, specific embodiments thereof have been shown
by way of example in the drawings and are herein described in
detail. It should be understood, however, that the description
herein of specific embodiments is not intended to limit the
invention to the particular forms disclosed, but on the contrary,
the intention is to cover all modifications, equivalents, and
alternatives falling within the spirit and scope of the invention
as described herein.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0013] Illustrative embodiments of the invention are described
below. In the interest of clarity, not all features of an actual
implementation are described in this specification. It will of
course be appreciated that in the development of any such actual
embodiment, numerous implementation-specific decisions must be made
to achieve the developer's specific goals, such as compliance with
system-related and business-related constraints, which will vary
from one implementation to another. Moreover, it will be
appreciated that such a development effort might be complex and
time-consuming but would nevertheless be a routine undertaking for
those of ordinary skill in the art having the benefit of this
disclosure.
[0014] The present invention represents a method for multi-stage
debulking and compaction of thick composite repair laminates made
from one or more polymeric-matrix composite materials. In one
embodiment, the method is applied to the repair of an existing
composite part. The method provides a composite part meeting the
same laminate quality requirements as a thick laminate made using
highly-pressurized autoclave processing. For the purposes of this
disclosure, the term "thick laminate" means a laminate made from
more than about 10 plies of polymeric-matrix composite
material.
[0015] Referring to FIG. 1 in the drawings, a pre-existing
composite part 101 is shown. It should be noted that composite part
101 may be planar or non-planar in form. A layer of release film
103 is applied to composite part 101 and a first plurality of
uncured plies 105 (only one labeled in FIG. 1 for clarity) of
polymeric-matrix composite material is applied to release film 103.
In a preferred embodiment, the number of uncured plies 105 making
up the first plurality of uncured plies 105 is no more than about
ten plies. The first plurality of uncured plies 105 makes up a
first ply stack 107. Uncured plies 105 may comprise "wet lay-up"
plies or pre-impregnated, i.e., "pre-preg" plies.
[0016] Referring now to FIG. 2, bleeder material (not shown) and a
sealing bag 201 is applied over first ply stack 107 and release
film 103 in a conventional manner. Sealing bag 201 is attached to
an exposed surface 203 of composite part 101 to create a
substantially air tight seal between exposed surface 203 and
sealing bag 201. A vacuum port 205 extends through sealing bag 201
to allow gases to be withdrawn from sealing bag 201 within the
substantially air tight seal between sealing bag 201 and exposed
surface 203. A vacuum assembly (not shown) is attached to vacuum
port 205, which evacuates gases, as represented by arrow 207, from
within the sealed volume of sealing bag 201. In a preferred
embodiment, vacuum at a level of two to three inches of mercury is
applied to the sealed volume of sealing bag 201. In addition to
applying vacuum, a heat source 209 heats at least first ply stack
107 to a desired debulking and compaction temperature. In a
preferred embodiment, sufficient heat is applied to first ply stack
107 by heat source 209 to raise the temperature of first ply stack
107 to a temperature of about 125 degrees Fahrenheit. First ply
stack 107 is maintained at the desired temperature, e.g., about 125
degrees Fahrenheit, under vacuum, e.g., about one to two inches of
mercury, for a time period sufficient to debulk and partially
compact first ply stack 107. In a preferred embodiment, first ply
stack 107 is maintained at the desired temperature and under vacuum
for about one hour. Subsequently, first ply stack 107 is preferably
maintained at the desired temperature under full vacuum, e.g.,
about 28 inches of mercury, for a period of time of about 30
minutes to further compact first ply stack 107. After the desired
period of debulking and compaction time, sealing bag 201, the
breather material, and any other ancillary processing materials are
removed from first ply stack 107 and composite part 101. First ply
stack 107 is now debulked and compacted.
[0017] It should be noted that the debulking and compaction
temperature is a temperature below a curing temperature of the
polymer-matrix composite material.
[0018] Referring now to FIG. 3, a plurality of ply stacks, such as
first ply stack 107, a second ply stack 301, and a third ply stack
303, are combined to form a ply stack assembly 305. Ply stack
assembly 305 may comprise any suitable, desired number of ply
stacks, such as ply stacks 107, 301, and 303. In the illustrated
embodiment, second ply stack 301 is formed by applying a plurality
of plies, preferably no more than about ten plies, to first ply
stack 107. A bag, such as sealing bag 201, is then applied to first
ply stack 107 and second ply stack 301. Vacuum and heat are then
applied to bagged first ply stack 107 and second ply stack 301
according to the method described herein concerning FIG. 2. Third
ply stack 303, as well as any desired ply stacks in addition to
third ply stack 303, are formed by the same method as second ply
stack 301.
[0019] Referring to FIG. 4, release film 103 (shown in FIGS. 1-3)
is removed and replaced with a bonding material 401. Bonding
material 401 is disposed between ply stack assembly 305 and exposed
surface 203 of composite part 101. Note that in this one method of
bonding ply stack assembly 305 to exposed surface 203. Bonding
material 401 also includes, and is not limited to: a layer of
adhesive paste or a layer of adhesive film disposed between ply
assembly 305 and exposed surface 203; and/or, adhesive material
disposed within ply stack assembly 305.
[0020] As depicted in FIG. 5, bleeder material and a sealing bag
501 is applied over ply stack assembly 305 and bonding material 401
in a conventional manner. Sealing bag 501 is attached to exposed
surface 203 of composite part 101 to create a substantially air
tight seal between exposed surface 203 and sealing bag 501. A
vacuum port 503 extends through sealing bag 501 to allow gases to
be withdrawn from sealing bag 501 within the substantially air
tight seal between sealing bag 501 and exposed surface 203. A
vacuum assembly (not shown) is attached to vacuum port 503, which
evacuates gases, as represented by arrow 505, from within the
sealed volume of sealing bag 501. In a preferred embodiment, full
vacuum, e.g., about 28 inches of mercury, is applied to the sealed
volume of sealing bag 501. In addition to applying vacuum, a heat
source 507 heats at least ply stack assembly 305 to a desired
curing temperature, which is dependent upon the particular
composite material being used. In one embodiment, sufficient heat
is applied to ply stack assembly 305 by heat source 507 to raise
the temperature of ply stack assembly 305 to a temperature of about
250 degrees Fahrenheit. Ply stack assembly 305 is maintained at the
desired temperature under full vacuum for a time period sufficient
to sufficiently cure ply stack assembly 305 and bonding material
401 to form composite laminate 601, shown in FIG. 6. In a preferred
embodiment, ply stack assembly 305 is maintained at the desired
temperature and under vacuum for about two hours. After the desired
curing time, sealing bag 501, the breather material, and any other
ancillary processing materials are removed from composite laminate
601, as depicted in FIG. 6. The cured ply stack assembly 305 and
the previous composite part 101 now form parts of composite
laminate 601, as the cured ply stack assembly 305 is adhesively
bonded to the pre-existing form of composite part 101.
[0021] It should be noted that the present method may also be
applied to the fabrication of a new composite part, rather than to
the repair of a composite part. For example, composite part 101 may
be replaced with a lay-up tool. Release film 103 is not replaced
with bonding material 401 prior to curing ply stack assembly 305,
so cured composite laminate 601 can be removed from the lay-up
tool.
[0022] It should also be noted that a damaged composite part 701,
shown in FIG. 7, may be machined or scarfed to define a recess 703
into which a ply stack assembly 705 is received, cured, and
adhesively bonded to composite part 701 to form composite laminate
707.
[0023] The particular embodiments disclosed above are illustrative
only, as the invention may be modified and practiced in different
but equivalent manners apparent to those skilled in the art having
the benefit of the teachings herein. It is therefore evident that
the particular embodiments disclosed above may be altered or
modified and all such variations are considered within the scope
and spirit of the invention. Accordingly, the protection sought
herein is as set forth in the description. It is apparent that an
invention with significant advantages has been described and
illustrated. Although the present invention is shown in a limited
number of forms, it is not limited to just these forms, but is
amenable to various changes and modifications without departing
from the spirit thereof.
* * * * *